Wall framing system

ABSTRACT

The present invention relates to an engineered lumber framing system of pre-fabricated components for construction of structures comprising: a first top plate comprising an end, the end including corners at variable angles forming a first stepped construct; and a second top plate comprising an end, the end including corners at variable angles forming a second stepped construct; wherein the first stepped construct fits into the second stepped construct forming a corner connection; and wherein the first top plate and the second top plate each comprise of a plurality of sheet layers. The corner connection comprises a haunched stub tenon-like corner joint.

FIELD OF THE INVENTION

This invention relates to the manufacture and use of a prefabricated structural framing system.

BACKGROUND

Timber framing is a routine method for construction of structures. Timber framing construction typically uses solid dimensional lumber, joined with nails to form framing structures. This method includes cutting of dimensional lumber at a construction site.

Difficulties of this prior art may include imperfection in positioning, orientation, and the dimensions of the pre-sawn lumber. During the construction of a structure, there are typically stages of significant instability of components requiring temporary bracing during assembly and construction. This is inconvenient, time consuming and adds to the cost of framing the structure. Bracing can introduce safety hazards and restrict the movement of people or materials at a construction site.

Cutting dimensional lumber at a construction site can also introduce hazards including injury during cutting, accumulation of dust, debris, and off-cut pieces, and tripping hazards associated with power cables. Generally, cutting equipment such as table saws may require sheltering from the elements, which may add to the cost of the construction.

Moreover there are limits on the size and height of structures framed using traditional dimensional lumber. Larger structures may require significantly different construction materials, equipment and techniques.

The production of traditional dimensional lumber includes growing, harvesting, sawing, drying and planing. All these steps have environmental impacts as they involve handling systems that produce waste products.

SUMMARY OF THE INVENTION

Embodiments of the present disclosure relate to an engineered lumber framing system for construction of prefabricated structures comprising: a first top plate comprising an end, the end including corners at variable angles forming a first stepped construct; and a second top plate comprising an end, the end including corners at variable angles forming a second stepped construct; wherein the first stepped construct fits into the second stepped construct forming a corner connection; and wherein the first top plate and the second top plate each include a plurality of sheet layers. The corner connection comprises a haunched stub tenon-like corner joint.

In another embodiment of the present disclosure, an engineered lumber framing system comprising: a corner post including an end, a first side, a second side, a first end edge between the end and the first side and a second end edge between the end the second side, and a corner wall; and a corner end wall including a first wall portion protruding beyond the end along the first end edge; and a second wall portion protruding beyond the end along the second end edge.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the present disclosure will become more apparent in the following detailed description in which reference is made to the appended drawings:

FIG. 1a shows a plan view of a corner post assembly.

FIG. 1b shows an axonometric view of a corner post assembly.

FIG. 2a shows a plan view of a 2×4 post assembly.

FIG. 2b shows an elevation view of a 2×4 post assembly.

FIG. 2c shows an axonometric view of a 2×4 post assembly.

FIG. 3a shows a plan view of a larger 2×6 post assembly.

FIG. 3b shows an elevation view of a larger 2×6 post assembly.

FIG. 3c shows an axonometric view of a larger 2×6 post assembly.

FIG. 4a shows a plan view of a header beam.

FIG. 4b shows a front view of a header beam.

FIG. 4c shows an axonometric view of a header beam.

FIG. 5 shows an elevation view of an assembled door opening and header.

FIG. 6a shows a plan view of a sill beam.

FIG. 6b shows a front view of a sill beam.

FIG. 6c shows an axonometric view of a sill beam.

FIG. 7 shows an elevation view of an assembled window opening and header and sill beam.

FIG. 8a shows a plan view of a corner plate assembly.

FIG. 8b shows an elevation view of a left top plate assembly.

FIG. 8c shows a plan view of the left top plate assembly.

FIG. 8d shows an elevation view of a right top plate assembly.

FIG. 8e shows a plan view of the right top plate assembly.

FIG. 8f shows a plan view of the top plate assembly.

FIG. 9a shows an axonometric view of the top plate assembly.

FIG. 9b shows an axonometric view of the corner post.

DETAILED DESCRIPTION

Engineered lumber such as plywood or oriented strand board (OSB) can have a reduced environmental impact due to the decreased footprint of natural resources required to make these products, for example there is a decrease in energy consumption and of exhaust gas emission. Engineered lumber can be produced with greater consistency than traditional solid dimensional lumber, which can also lead to less material waste. Additionally, engineered lumber can achieve larger dimensions than traditional solid dimensional lumber.

The framing system of the present invention includes prefabricated OSB or similar engineered beam assemblies including corner posts and top plate assemblies. In another embodiment, the system further includes top plate locking plates, posts with varying dimension including 2×4 posts, 2×6 posts, etc., window headers, window sills, door headers, or door sills. The system can be used to build garages, houses, condominiums, and similar structures that would otherwise be framed using traditional dimensional lumber framing techniques and materials.

In one aspect of the invention, the framing system of the present invention includes a kit of all the pre-fabricated components made to fit certain dimensions of a construction project with instruction manuals or videos. The kit may be shipped to a construction site for ease of use and timely construction.

In one embodiment of the present invention, the engineered framing system includes a corner post box structure made up of OSB walls enclosing an insulated core. The box structure gives the corner post compression, torsion and flexion strength. In another embodiment, the tight enclosure of an expanded insulation, for example polystyrene (EPS) foam, can provide some additional compressive strength. Corner post sidewalls are cut to size for a desired application and may be connected together using a fastener, such as glue and staples. The insulation is configured to fit tightly within the cavity of the box structure. The corner post may be formed of straight walls with square corners and is stable. The corner post includes an end, a first side, a second side, a first end edge between the end and the first side and a second end edge between the end the second side, a corner wall and insulation. There is a corner end wall including a first wall portion protruding axially beyond the end along the first end edge, and a second wall portion protruding axially beyond the end along the second end edge. The protruding portions are referred to as the wings of the corner post. The wings are vertical extensions of two adjacent corner post sidewalls. These wings form an axially projecting outside corner, which provides top plates accurately aligned into the corner post.

In another embodiment, the engineered framing system further comprises a support element protruding outwardly from a third side and extending axially along the corner and another support element protruding outwardly from a fourth side and extending axially along the corner. With reference to FIG. 1, these protruding portions are also referred to as the cleats 160. Along the vertical height of an inside corner of the corner post, there may be cleats for subsequent wall board attachment. The framing system may also include cleat supports 150.

In one embodiment, the system further includes a top plate assembly supported on a corner post. Each end of a top plate assembly includes connectors, providing stable and accurate engagement of two adjacent top plate assemblies with the corner post. A corner post includes wings that extend up vertically beyond the end edge of the corner post when installed. With reference to FIG. 2, a connector having a notch on its side 230 provides accurate fitting with the wings of the corner post. In one embodiment, a connector included a first top plate, an end, the end including corners at variable angles forming a first stepped construct; and a second top plate, a second end, the end including corners at variable angles forming a second stepped construct. The first stepped construct fits into the second stepped construct forming a corner connection. The connector has a stepped construct also referred to as a zig-zag shape, a stepped mating profile or a stepped profile. The shape may form a haunched stub tenon-like corner joint. The stepped profile may be created by a first top plate assembly matching the corresponding stepped profile in a second top plate assembly. A stepped profile in the first top plate is the same as, but in the reverse of the stepped profile in the second top plate providing accurate and secure positioning of the top plate assemblies relative to each other and the corner post. The top plate assembly is may be a composite beam of pre-cut OSB, assembled and fastened such as by gluing or stapling.

In an example configuration, the beam assembly is a glued and stapled assembly of eight sheets of OSB with the individual sheets oriented vertically (i.e. a plurality of sheets positioned face to face in parallel planes with their fiber strands oriented and aligned with the longitudinal axis of the sheets, for example in the orientation of a laminate) and an additional locking strip of OSB oriented horizontally (i.e. a sheet positioned flat over the edges of one side of a plurality of sheets) and spanning the assembly. This provides an added flexion strength in the vertical direction, when the beam is installed.

In another embodiment, the engineered lumber framing system includes a recess also referred to as a cavity or a depression on the surface of the top plate. A top plate locking plate in an L or elbow shape made from OSB may be inserted into said recess. The top plate locking plate is attached to the top of the corner joint once two adjacent top plate assemblies are attached to the corner post. The top plate assembly includes a recess proximal the ends into which the top locking plate may be installed for a substantially flush arrangement with the corner post. In one embodiment, for example, the recess may be formed proximal to the terminating end of the top plate assembly. The top plate locking plate may be fastened using screws. The top plate locking plate gives additional load and torque support to the structure and provides a flat top surface, suitable for further construction of roofing, support joints, flooring or higher wall structures.

With reference to FIG. 8e , in an example configuration, three of strips extend to the full length of the top plate assembly, four adjacent strips of the beam are shorter at an intermediate length, and a single strip is the shortest. These eight strips are assembled to form a top plate assembly with end connectors and extensions.

During assembly of the structure fasteners such as screws, nails, glue, staples etc. may be used. Compared to traditional nailed assembly, screws can provide greater strength, avoiding fatigue and workout. The shape of the connectors allows for the beam assembly in either order, left then right or right then left.

The orientation and shape of the top plate assembly and the top plate locking plate provides a structure where the majority of the cut edges of the OSB are covered and the majority of the outer exposed structure comprises of a laminate face of the OSB. Additionally, the orientation and shape of the components is such that all fasteners can pass through and abut the laminate face of the OSB. Therefore, fasteners entering the edges of the OSB are avoided.

The cut edges of OSB may be weak and susceptible to damage and delamination. The present invention hides the majority of the cut edges of the corner post/beam assembly and avoids screws that go through the cut edges.

Assembly posts for example 2×4 posts, 2×6 posts and other traditional lumber dimensions are formed as fastened stacks or boxes of OSB in similar dimensions as traditional dimensional lumber. Posts can also be cut to non-traditional lumber dimensions. Any post can include internal insulation. The posts may also include internal bracing for greater strength.

In another embodiment, the engineered lumber framing system includes corner posts, 2×4 posts, and 2×6 posts with mortise-like recesses to quickly, accurately, and securely attach to horizontal components.

With reference to FIG. 4c , window, door headers and sills are formed of fastened stacks or boxes of OSB. The windows, headers and sills can include tenon-like projections 450 configured to fit in mortise-like grooves 460 in the appropriate mating post elements. These tenon-like projections may be formed as a stack of vertically oriented OSB strips for high flexion strength.

The framing system provides improved loading strength and insulation relative to traditional framing with dimensional lumber. In addition, the worksite may be safer by avoiding cutting, saw cabling, dust and off-cut debris as well as providing stable and free-standing framing at all stages of construction, which avoids the need for temporary bracing and additional construction workers.

On a construction site where additional structural requirements may be needed, for example earthquake resistance or hurricane resistance, the framing system of the present invention may include additional materials for example anchoring to prevent shear or roof-lift. In addition, the framing system components may be treated before shipping, for example treatment may include coatings such as fire-resistant, moisture-resistant, or insect-resistant coatings. Coating of the framing structure components can occur after fabrication and cutting providing a complete barrier covering the entire surface of the component.

Holes for conduits for electrical or plumbing may be drilled into framing system components before or after assembly. Drilling before assembly can facilitate a complete coating barrier if coating is required.

Testing Data

Example walls were built and tested to structural failure.

The framing system components used for testing were 8 ft×10 ft walls for racking shear tests and 4 ft×10 ft walls for axial and transverse load tests.

The walls were manufactured using 7/16 inches thick OSB fastened 6 inch on center (o/c) around a perimeter and 12 inches o/c elsewhere with 2 inches long wire weld nails.

Description Specimen Result Axial load Test #1 40,200 lbs Test #2 37,400 lbs Test #3 35,000 lbs Transverse load Test #1 122 psf Test #2 120 psf Test #3 114 psf Racking shear load Test #1 2360 lbs Test #2 3000 lbs Test #3 2360 lbs

LEGEND FOR FIGURES Number Name 110 corner post sidewall 120 corner post sidewall 130 corner post sidewall 140 corner post sidewall 150 cleat support 160 cleat 170 insulation 180 corner post cap 210 post faceplate 220 post faceplate 230 post side member 240 post core member 310 post faceplate 320 post faceplate 330 post sideplate 340 post core member 410 header locking strip 420 bottom header locking strip 430 header member 430 header side member 440 header core member 450 header core member 510 sill locking strip 520 sill core member 530 sill side member 560 sill pocket 610 top plate locking plate 620 right top plate locking strip 640 right top plate member 650 right top plate member 660 right top plate member 670 right top plate member 680 left top plate locking strip 690 left top plate member 700 left top plate member 710 left top plate member 720 left top plate member

FIGS. 1a-1c show the corner post assembled as a box with an optional insulation core. The inside corner of the corner post includes cleats for subsequent hanging of wall panels. Opposite the inside corner is the outside corner. At the top of the post, the sidewalls of the outside corner project vertically when the post is installed, beyond the other walls of the post to form the wings.

FIGS. 2a-2c and 3a-3c show support posts. The support posts can optionally include an internal cavity (not shown) to contain insulation.

FIG. 4a-4c shows a beam as a glued assembly of sheets of material. In one embodiment, there are a plurality of sheets positioned face to face in parallel planes, such as in the orientation of a laminate (vertically oriented when normally installed) and at least one sheet positioned over the side edges of the plurality of sheets (horizontally orientated when normally installed). Some sheets in the core of a beam project beyond the side sheets to form an integral tenon-like tab at the end of the top plate. FIG. 4 also shows a support post with a recess to quickly, accurately and securely receive the tab of a corresponding header top plate. The header beam can optionally include an internal cavity (not shown) to include insulation.

FIG. 8a-8f shows a top plate assembly. The top plate may be a glued assembly of parallel (i.e. vertically when installed) oriented top plate members. FIG. 8 shows an example of a plurality of vertically oriented layers top plate assemblies and a horizontal top plate locking plate. Each top plate assembly has integral connector features at each end, illustrated as a haunched stub tenon-like corner joint. Typically a single top plate assembly will have one end in the form shown as a Right Top Plate and one end in the form shown as a Left Top Plate. 

What is claimed is:
 1. An engineered lumber framing system for construction of prefabricated structures comprising: a first top plate comprising an end, the end including corners at variable angles forming a first stepped construct; and a second top plate comprising an end, the end including corners at variable angles forming a second stepped construct; wherein the first stepped construct fits into the second stepped construct forming a corner connection; and wherein the first top plate and the second top plate each comprise of a plurality of sheet layers.
 2. The engineered lumber framing system in claim 1, wherein the corner connection comprises a haunched stub tenon-like corner joint.
 3. The engineered lumber framing system in claim 1, further comprising: a top plate locking plate; the first top plate further comprising a recessed portion along the external surface; the second top plate further comprising a recessed portion along the external surface; and wherein the top plate locking plate fits into the recessed portions of the first top plate and the second top plate.
 4. An engineered lumber framing system comprising: a corner post including an end, a first side, a second side, a first end edge between the end and the first side and a second end edge between the end the second side, and a corner wall; and a corner end wall including a first wall portion protruding beyond the end along the first end edge; and a second wall portion protruding beyond the end along the second end edge.
 5. The engineered lumber framing system in claim 3, further comprising: a first top plate supportable on a corner post, the first top plate including an end and a first side notch, the first side notch having a recess that accommodates a first wall portion; and a second top plate supportable on a corner post, the second top plate including an end and a second side notch, the second side notch having a recess that accommodates a second wall portion.
 6. The engineered lumber framing system in claim 3, wherein the corner post further includes: a third side opposite the first side, a fourth side opposite the second side, a corner between the third and fourth side, a first support element protruding outwardly from the third side and extending along the corner, and a second support element protruding outwardly from the fourth side and extending along the corner. 